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www.renewableenergyfocus.com January/February 2010

Abu Dhabi's Masdarplan takes shape

inside:

OFFSHORE WIND: DO WE

HAVE WHAT IT TAKES?

INNOVATIONS IN PVINSTALLATION TECHNOLOGY

Who's got money for cleantech?

Helping the UK EfW

industry succeed

Night view of Masdar City's flagship development the Masdar institute under construction.


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Feature article

Innovations in

PV installationtechnologyPART 1:CELL MANUFACTURERS CONTINUE TO DRIVE DOWN THE COST OF MANUFACTURING

AND BOOST EFFICIENCY OF THEIR PRODUCTS. BUT ITS FOR NOTHING IF INSTALLATIONCOSTSAND PERIPHERAL DEVICES THAT HARVEST USEABLE ENERGY FROM THE

CELLSNEGATE THE MANUFACTURING COST SAVINGS, AND ADD TO THE PRICE FOR THE END

USER. JOYCE LAIRD LOOKS AT WHAT IS BEING DONE ON THE USER END TO MOVE PV CLOSER

TO A UNIVERSAL REALITY ONE THAT MEETS ALL DEMANDS AT A REASONABLE COST.

New devices for all installations

Innovations in harvesting

Many peripheral devices are being developed that boost the efficiency of

PV systems. National Semiconductor is well known for semiconductor

technology and IC devices and their Renewable Energy Group, based in

Santa Clara, CA is taking IC technology into photovoltaics.

We do this by employing distributed electronics into the PV systems to

provide higher harvesting performance, Ralf Muenster, director of the renew-

able energy group says. We are agnostic to the underlying technology. The

goal is to fix some of the shortcomings of all photovoltaic systems, he adds.

The shortcoming with the basic inverter technology is that even the

smallest mismatch has a very disproportionate impact on the energy

harvest. It has been found that as little as 1.5% shade can cause a 17%loss of output. And a major issue that causes 10% malfunction can reduce

the whole system output by 50% or more.

SolarMagic from National Semiconductor is a small device with just two

inputs and two outputs which can be retrofitted into existing instal-

lations or installed along with new installations behind panels. It takes

whatever is being delivered by the panels, whether 100% or 50% energy

output and converts it to the optimum current to the inverter. We typi-

cally recoup about 50%-60% of the power that would otherwise be lost,

Muenster says.

He notes that ultimately the best solution will be to put the ICs boardinside the junction box thats already on the back of the panel. The

company is currently working with panel manufacturers on this so expect

to see some fully integrated solutions to come out in 2010. But, until that

is available, SolarMagic can help overcome impairment issues.

We are not out there to compete. We offer our science to all panel

manufacturers. We teach them how to create the PCB and integrate

it reliably so when its put into a junction box it will last 25 years. We

provide the electronics know-how and our solution fits everywhere

from residential and commercial to utility plants..

Another power harvesting innovation comes from Solar Edgebased in

Herzelia, Israel. They developed a three-fold architecture that consists

of PowerBoxesperforming module-level MPPT (maximum power point

tracking), a highly-reliable inverter, and a web portal for module-

level monitoring and fault detection. The PowerBox is embedded into

each module by the module manufacturers instead of the junction

box. It can also be retrofitted by PV installers onto c-Si, thin film and

CPV modules.

Photovoltaic systems are highly ineffective. There has been a lot of inno-

vation in improving the cells themselves, but not from the total systempoint of view, Lior Handelsman, vice president of product strategy &

business development, says. If the whole PVA is connected to one

inverter the inverter cant optimise the energy harvesting from each

individual module. This causes an energy loss of between 2% to 25%.

Solar Edge have developed a different way to harvest power from

PV systems. The company has moved the power harvesting to each

individual module. Instead of feeding the whole string into one large

inverter, Solar Edge has developed a small chip that goes into the

junction box that is on the back of every module.

This leaves the inverter only transforming DC to AC current for final gridconnection. The power is matched to the inverter and we know exactly

how each cell is functioning. A cell that has issues for any reason does

not drag down the performance of the whole string, Handelsman says.

Also, because of this, while any inverter can be used, it does open the


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PV/installations

option to use a simple, less costly inverter, while gaining from 2% to

25% more energy output. Our technology supports any type of PV

modules up to 100 volt.

Fixturing

You cant have solar power without some way to mount it. Probably one

of the most foremost companies looking at this aspect is Schletter Inc.,

headquartered in Germany. The company provides racking fixtures for

everything from residential rooftops to large ground mounts, including

custom installations. They are currently creating more modular products to

give integrators turnkey racking solutions for solar projects.

Many Schletter racks are delivered up to 70% pre-assembled, Sven

Kuenzel, senior sales manager says for the new US plant based in Tucson,

AZ. Structurally, it is becoming more of a plug-and-play product. That

gets the mounting time way down. The labour is where all cost reduction

has to happen. There comes a point where fixturing cant get any lower in

manufactured cost, and the same goes for the solar cell manufacturers. It

is the installation where the cost can be addressed. Make everything faster

to install and more reliable, he says.

When talking about the solar market in general, Sharp does it all; complete

PV manufacturing from si-PV to CIGS. Ron Kenedi, vice president, Sharp

Solar Energy Solutions Group, Huntington Beach, CA, says that while notan installer, Sharp is doing things to help installers.

We are making our frames easier to use in terms of commercial system

installations and we are also offering a complete system for residen-

tial called OnEnergy, which includes the framed solar modules and the

inverter. It is delivered on site ready to go so the contractor just installs

it, Kenedi says.

Sharps OnEnergy solar system features UL-listed, rail-by-rail integrated

grounding, eliminating the need for connecting a ground wire from module

to module throughout the entire array. It has pre-cut, pre-drilled racks, fewer

rails and mounting hardware and requires less ground lugs and copperwiring. This reduces overall system costs by cutting installation time.

On the utility scale side we are working very closely with contractors to

design the best systems for our thin film modules. Weve come up with

new ways to install, which eliminate concrete. A special machine punches

the rack into the ground and then it just installs the modules, Kenedi says.

System Integrators at all levels

System integrators have the unique position of viewing what is happening

in the industry as a whole, and how it affects the overall progression of full

solar power utilisation. All take customers from feasibility analysis to design

and system installation.

Borrego Solar Systems, Inc. headquartered in Lowell, MA is one such inte-

grator. We focus on commercial buildings and municipalities such schools,

and we are technology agnostic. We need to be free to take advantage of

the best solution for every project, Ike Hall, ceo, says.

Hall notes that he sees the power conversion area as the fastest growing new

technology. Many companies are coming up with ever better ways to make

power conversion smarter. Probably one of the most exciting things weve

seen is transmitting the performance data over the power lines rather than

installing a separate data-com, which is very difficult, he says.

Typically all customers are looking for a good return, Hall adds. If we cant

deliver this, then its not going to work. After that, the second thing we do is

try to mitigate the risk for the customer. We need to ensure that this whole

system and all of its parts is going to perform for 25 years.

To address this, Borrego favours mature technology and real balance sheets,

whether cell manufacturers or the latest in peripheral system devices. Inves-

tors are not willing to take financial risks with a VC backed company that

is not fully warranted.

We feel as the market matures, more emphasis will be on buying power

rather than buying systems. Ultimately we want to be a full energy service

area to all markets, Hall says.

Innovateus Solar LLC is another world wide distributor of PV products that

works directly with companies for commercial rooftop installations.

Finding the right fit for the right use is the companys foremost goal. The first

it looks at is the type of roof. Second, the geographical location. This dictates

what type of solar panels would work best and what type of fixturing.

Borrego takes customers all the way through feasibility analysis to design and system installation (courtesy of Borrego Solar Systems, Inc).


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PV/installations

If the roof is an architectural metal one, we would start out recom-

mending thin film products, like those from Uni Solar. Its thin film and

flexible and easily applied to metal, Thomas Justin Kanczuzewski, exec-

utive vice president, says. If it is white reflective like a TPO or PVC we

suggest a product like Solyndra. For maximum power in limited space

on a sturdy roof, wed recommend a high effi ciency crystalline panel. Both

price and quality are big definers.

Charley Farmer, vice president of design for Meridian Solar, Inc. believes that

the most interesting technology he has seen this year are the PV modules

manufactured by the Solyndra company. What I find fascinating is that

Solyndra created a completely different form factor that solved the traditional

problems faced by CIGS PV modules. In commercial installations with very

large span roofs like warehouses with TPO (thermoplastic polyolefins) roofing,

owners definitely do not want their roof penetrated in any way. Also, they

cant carry as much weight as smaller commercial roofs. The Solyndra system

is extremely light weight about 3 lbs. per sq. ft., where a traditional ballast

system could be 10lbs-20lbs. And it installs by snapping together like Lego,

with no roof penetration. We are pretty excited about this product.

The second most interesting technology Farmer says is the rise of the indi-

vidual inverters, as well as the latest in DC-DC converters, including National

Semiconductors SolarMagic and Enphase micro-inverters. I think you will

see these companies grabbing more of a market share. We have used the

Enphasetechnology on about 15% of our installs to date.

As for the market itself, Farmer has a strong opinion on regulation. A signifi-

cant number of solar systems are being installed without using a licensed

structural engineer, to sign off on the fact that the building can withstand

the additional load put on that building. The US currently has no national

requirements, which can be dangerous. For example at Meridian we hire an

independent structural engineer to do our own analysis on every project to

make sure that public safety is never at risk by installing a specific system.

Installation Partnering

Pristine Eco Systems, based in East Hampton, NY, USA is strictly focused on

installations. Greg Darvin, owner, says that with his construction background

he partnered with a licensed electrician. Because of such dual expertise in

electric and construction, Pristine takes a very holistic view of solar: We set

a realistic goal. We go through every power usage avenue the customer

currently uses before recommending a solar array. It not only needs to be

aesthetically good, but it needs to be fixtured properly, and there are a lot of

structural things that need to be taken into consideration.

Like many other integrators and installers, Darvin believes that the biggest

problem with the industry is lack of regulation. Taking the USA as an

example, the only form of certification is NABCEP (North American Board of

Certified Energy Practitioners). Pristine is one of the approximately 800 compa-

nies in the USA that are NABCEP certified. We need a Federal board and

individual state boards. There really are none at this point other than general

energy, which doesnt address the unique needs of solar. It need solar-specific

expertise to ensure things are being done right, Darvin says.

Pro-Tech Energy Solutions LLC and the Whitman Company, both located

in NJ, USA, are another successful solar installation partnership.

John Drexinger, president of Pro-Tech says that since his partnership with

Whitman, the companies have built over 11 MW of solar in New Jersey.

Having a partner that is expert in construction and physical engineering is

critical. It is extremely important to have experts in all facets of a project, not

only the power side, he says.

Barry Skoultchi and Carey Ruetsch (Whitmans president and director respec-

tively) agree that partnering with Pro-Tech creates a very well rounded

offering to commercial and industrial companies that decide to go the solar

route. Whitman has been in business for over 25 years as a multi-disciplined

engineering firm. We are their main engineering support for Pro-Tech on the

design side for structural engineering on the rooftops, Ruetsch says.

One thing that the Pro-Tech/Whitman alliance does that is slightly different

than other installers is perform audits using different solar panel brands in

different geographical locations. You cant stick to any one technology.

National Semiconductor provides devices that maximise PV system energy harvest by employing

distributed electronics (courtesy of National Semiconductor, Renewable Energy Group).

Click through

Interested in further information on this topic? Go to http://tinyurl.com/

ykga5b2. Or click on the following links from the digital issue of the

magazine:

PV manufacture: synergy without dependence

http://tinyurl.com/pckey7

Can the solar photovoltaic industry beat the economic downturn?

http://tinyurl.com/pftuok

How to handle defective PV cells and wafers http://tinyurl.com/ofsd3s

Solar PV Innovation: the new buzz http://tinyurl.com/y9usf9x

There comes a point where fixturing

cant get any lower in manufactured

cost, and the same goes for the solar cell

manufacturers. It is the installation where

the cost can be addressed. -

Sven Kuenzel, Schletter Inc.


5/5renewable energy focus January/February 2010 37

PV/installations

You dont know best fit until you do site evaluations to find it. We check out

everything available. When the customer is putting up money, they need to

trust you, Drexinger says.

Future Concepts

Cool Earth based in Livermore, CA, USA has one of the most unique

concepts in utility level solar generation to date - solar balloons. The

company didnt start out to develop a solar balloon concentrator, only to

experiment with the lowest cost ways to effectively capture protons and

make electricity. It simply evolved.

The balloon is the concentrator. The whole front of the balloon surface

is clear plastic while the inside surface is aluminum coated, Rob Lamkin,

CEO, says.

When pointed toward the sun, this inflated balloon concentrates the light

and focuses it to an internal PV solar cell that captures the photons and

converts them into electricity. The inflated solar concentrator is 10 feet in

diameter, but the actual solar cell material is only 8 inches across. The solar

cell at the heart of the receiver is space-grade silicon or compound semicon-

ductor material, such as that used in the SolFocussystem.

Cool Earth says it will be building its first commercial utility scale power

plant next summer. Lamkin says that its first plant will be one or two MW

(to prove the technology) with subsequent plants at the 10 MW level. We

are not looking at selling equipment. We will be selling power to directly to

large utilities from our solar farms, he says (see part two of this article in the

March/April issue for installations on the distributed/commercial; as well as the

utility side of PV solar).

Wherever you look today, whether utility, commercial or residential, installa-

tion innovations are being developed to make solar power more cost effi-

cient and safer to use. With both module, fixturing and device innovators

bringing new products to the market, there is a lot to take advantage ofwhen choosing the best fit for specific applications.

NB: Part two of this article in the March/April will focus on specific installa-

tions on the distributed/commercial; as well as the utility side of PV solar.

About the author:

Based in California, Joyce Laird has been writing for a wide range of industrial magazines for

over a decade. Her extensive background in the semiconductor industry created a perfect

transition to covering developments in photovoltaics.

The shortcoming with the basic inverter

technology is that even the smallest

mismatch has a very disproportionate

impact on the energy harvest. It has been

found that as little as 1.5% shade can

cause a 17% loss of output.

THE RENEWABLES SHOW IN THE ENERGY CITY ABERDEEN 19/20 MAY 2010

All-Energy 2010 the UKs largest renewable energy exhibition and conference looks forward to welcoming you as anexhibitor or visitor. 5,500 from 60 countries attended All-Energy 09 with its 380+ exhibiting companies from 14 countries and

more than 250 conference speakers. The major exhibition features technology across the full range of renewable energy devices;

and the free-to-attend conference looks at issues and challenges facing the industry and at renewable energy sources from

multi-million pound offshore projects to microgeneration. Networking opportunities abound.

Be there!See regularly updated information at: www.all-energy.co.uk

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